Holistic implementation of resource-efficient moulding processes

Project description and research content

The ESF junior research group "Holistic implementation of resource-efficient moulding processes" is funded by the European Social Fund (ESF) and serves to support the metalworking industry in Saxony. The project includes interdisciplinary research work on modern moulding processes. In tandem projects, a doctoral student in economics and a doctoral student in engineering work together on four main topics. The focal points of the Chair of Industrial Management / Production Management and Logistics include:

Evaluation and implementation of processes for low-temperature waste heat utilisation

The aim of the tandem research project is to develop suitable technologies for low-temperature waste heat utilisation (80 °C to 250 °C) in the foundry industry or to modify existing technologies. Furthermore, recommendations for the sustainable utilisation of these systems are to be derived. The recommendation matrix to be created for foundries takes into account both the waste heat utilisation technologies already installed in the foundries and the expected amount of low-temperature waste heat emitted and is based on technical, economic and ecological aspects.

The possibilities of recording the relevant energy and material flows are to be developed using foundry companies as an example. The aim is to achieve a holistic balance that includes economic, technical and ecological aspects. One focus is on process simulation and optimisation models for low-temperature waste heat utilisation, using the Umberto NXT software, among others. The focus is on technologies for the thermal utilisation of waste heat, such as heat storage, heat exchangers or pumps, but also technologies for the conversion of waste heat into electricity, e.g. OCR or Kalina processes, which are tailored to the special requirements of the foundry industry.

Development of a cross-value-added process and quality management system for the production and processing of Mg semi-finished products

The aim of the tandem research project is to create a process chain for the heat treatment and calibre rolling of application-oriented Mg semi-finished products. In addition to the technological development of the forming process, it is important to coordinate the upstream and downstream process steps and to ensure that the quality of the semi-finished Mg products is in line with market requirements.

The aim is to develop a corresponding quality management system for the production and processing of cast-rolled semi-finished products made of magnesium alloys using the example of magnesium strip production. The focus of the investigation is on empirical studies. The experience gained is to be generalised to such an extent that it can also be used for other process technologies. This should simplify and accelerate the implementation of novel technological processes in operational practice, where comprehensive QM is required, which is often a significant hurdle.

Under the technical leadership of Prof. Dr Michael Höck, Wiebke Berkel, M.Sc. and Dipl.Kffr. Claudia Kawalla were entrusted with the processing of the work packages.

Publications

C. Kawalla, M. Ligarski, M. Höck, Supply chain quality management of automotive components. Scientific Papers of Silesian University of Technology. Organisation and Management Series. 133 (2019) 69-83.

C. Kawalla (2018): Development of a Supply Chain Quality Management Model for Innovative Construction Materials. Diss. Freiberg University of Mining and Technology.

C. Kawalla, M. Höck, M. Ligarski, Supply Chain Quality Management of Magnesium Components: Concept, Examples and Recommendations. Materials Science Forum 941 (2018) 657-662.

C. Kawalla, W. Berkel, R. Kawalla, M. Höck, M. Ligarski, Material flow cost accounting analysis of twin-roll casting magnesium strips. Procedia Manufacturing 15 (2018) 193-200.

C. Kawalla, M. Ligarski, M. Höck, Quality management over the value chain of magnesium ready-to-assemble components, in: R. Kawalla, U. Prahl, M. Moses, H. Wemme (Eds.): MEFORM 2018 - Ressourceneffiziente Werkstoff- und Umformtechnologien, 2018, pp. 78-84.

M. Moses, C. Kawalla, R. Kawalla, M. Höck, Development of an innovative and quality-focused production technology for magnesium wire. Material Science Forum 918 (2018) 34-39.

C. Kawalla, M. Teuber, M. Höck, Empirical Examination of the Formation of Mechanical Properties of Heated Twin-roll-cast Magnesium Strips. In: D. Orlov, V. Joshi, K. Solanki, N. Neelameggham (eds) Magnesium Technology 2018, Springer, Cham.

C. Kawalla, M. Höck, M. Ullmann, C.M Ringle, An Empirical Examination of the Thickness Profile Formation of Twin-Roll-Cast Magnesium Strips. Archives of Civil and Mechanical Engineering 18(1) (2018) pp. 227-234.

C. Kawalla, M. Hoeck, Quality assurance system for hot rolled TRC magnesium strips. Scientific Papers of Silesian University of Technology. Organisation and Management Series. 100 (2017) 171-179.

C. Kawalla, M. Ullmann, M. Hoeck, Procedure to analyze the formation of segregations using the PLS-SEM approach. Key Engineering Materials 746 (2017) 75-83.